U.S. patent number 10,645,939 [Application Number 14/563,517] was granted by the patent office on 2020-05-12 for low profile water bath co-extrusion process for sausage manufacturing, and machines for use therewith.
The grantee listed for this patent is J & B Sausage Company, Inc.. Invention is credited to Shawn Brammall, Danny Janecka.
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United States Patent |
10,645,939 |
Brammall , et al. |
May 12, 2020 |
Low profile water bath co-extrusion process for sausage
manufacturing, and machines for use therewith
Abstract
A low profile water bath co-extrusion process for sausage
manufacturing is disclosed, along with machines for accomplishing
this process. The process is an automated assembly line which
begins with co-extruded food product, such as a sausage emulsion
coated with collagen and finishes with cooked, boxed, packaged link
sausage. The process includes the steps of co-extrusion, linking
and cutting the co-extruded food product to individual links.
Following these steps and prior to a liquid smoking step, the
casing is prepared by steps which includes chemical treatment of
the individual links in a water bath, while dehydrating the product
in a salt solution, the water bath being a two-part process and
following the water bath using a forced hot air drying step.
Machines disclosed include a modification of prior art screw driven
water bath and a novel roller/conveyor forced hot air drying
assembly that subjects individual links of a co-extruded food
product to a rolling motion while simultaneously being transported
horizontally and being subject to forced hot air drying.
Inventors: |
Brammall; Shawn (Waelder,
TX), Janecka; Danny (Waelder, TX) |
Applicant: |
Name |
City |
State |
Country |
Type |
J & B Sausage Company, Inc. |
Waelder |
TX |
US |
|
|
Family
ID: |
70612587 |
Appl.
No.: |
14/563,517 |
Filed: |
December 8, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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61912871 |
Dec 6, 2013 |
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61969487 |
Mar 24, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65G
17/24 (20130101); A23P 30/25 (20160801); A23B
4/0526 (20130101); A23L 13/65 (20160801); A23L
1/3103 (20130101); A22C 13/0016 (20130101); A22C
11/02 (20130101); A23B 4/031 (20130101); A23L
29/284 (20160801); A22C 11/008 (20130101); A23L
13/62 (20160801); A23V 2002/00 (20130101); A22C
2013/0023 (20130101) |
Current International
Class: |
A22C
13/00 (20060101); A22C 11/00 (20060101); A23B
4/03 (20060101); A22C 11/02 (20060101); B65G
17/24 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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3420764 |
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Dec 1985 |
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DE |
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0580232 |
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Jul 1993 |
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EP |
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Primary Examiner: Stulii; Vera
Attorney, Agent or Firm: Jackson Walker LLP
Parent Case Text
This is a utility patent application claiming the benefit of and
priority from U.S. provisional patent application Ser. No.
61/912,871, filed Dec. 6, 2013, and Ser. No. 61/969,487, filed Mar.
24, 2014.
Claims
The invention claimed is:
1. A process for producing a collagen encased food product
comprising: (a) providing a low profile water bath assembly having
first and second compartments, the first compartment for containing
a first heated aqueous solution, the second compartment for
containing a second heated aqueous solution; (b) co-extruding of a
food emulsion and coating the food emulsion exterior with a
collagen and, optionally, a cross-linking agent, producing a linear
coaxial collagen coated food member; (c) brine bathing, linking and
cutting the linear food member into multiple links; and (d)
contacting the collagen coated food links in the first compartment
of the water bath assembly with the first aqueous solution for at
least partly coagulating the collagen, the first solution having a
pH of 0.8 to 3.2, a salt content of 22% to 26% measured by a
refractometer, at a temperature of 120.degree. F. to 140.degree. F.
for a time sufficient to reach a temperature in a preselected
interval temperature range, wherein the collagen coated links are
gently agitated and carried from a first point, where they are
received in the first compartment to a longitudinally spaced apart
second point, where they are transferred to the second compartment;
and (e) contacting the collagen coated food links with the second
aqueous solution, the second aqueous solution being a non-acidic
solution to help prepare the collagen for smoking and for removing
at least some of the salt of the first aqueous solution, the second
solution comprising an aqueous solution of 12 to 22% food grade
phosphates refractometer, the second aqueous solution having a pH
of 7.0 to 9.0, and temperature of 125.degree. F. to 150.degree. F.,
wherein the collagen coated food links are gently agitated and
carried from a first point where they are received from the first
compartment to a longitudinally spaced apart second point, where
they are ready for transfer to a subsequent process step.
2. The process of claim 1, further including a forced hot air
pre-smoke drying step, a liquid smoking step, and a forced hot air
post-smoke drying step after the smoking step; and wherein the
pre-drying step includes providing a roller conveyor oven and
placement of links on a roller conveyor oven and subjecting them to
an air temperature of 130.degree. F. to 220.degree. F., with a
humidity in the range of 5% to 15%, to evenly dry the product while
rolling the individual links to maintain a round cross section, the
pre-dry time for product in the roller conveyor being 2 to 10
minutes; and wherein the post-drying step includes the step,
following the liquid smoking step, of providing a roller conveyor
oven with an oven set at temperature of 160.degree. to 210.degree.
F., with a humidity in the range of 5% to 15%, the post-dry time
being 2 to 10 minutes; while rolling the individual links and
subsequently packaging, completing cooking, and chilling the food
product.
3. A sausage manufacturing process comprising: forming a linear
food member by co-extruding a meat emulsion in a collagen casing;
bathing the linear food member in a brine; cutting the linear food
member into multiple individual links; transporting the multiple
individual links to a first heated water bath assembly, the first
heated water bath assembly comprising a first compartment or
section and a second compartment or section, the first section
having a pH control, a dissolved solids control and temperature
control; first heating the multiple individual links in the first
section in a first acidic aqueous salt solution at a temperature,
pH and for a time to help coagulate the collagen's protein to set
or bond the layers of collagen to one another and to the emulsion
while gently agitating and moving the links at a controlled speed
horizontally; and second heating the multiple individual links in
the second section in a non-acidic aqueous solution at a
temperature, pH and for a time sufficient to help remove at least
some of the salt and acid of the first heating and to prepare the
casing for smoke take up while gently agitating and moving the
links horizontally at a controlled speed.
4. The sausage manufacturing process of claim 3, wherein the first
section of the first heated water bath assembly includes a first
screw drive and the second section includes a second screw
drive.
5. The process of claim 4, further including a first dry heating of
the multiple individual links in a roller conveyor forced hot air
drying assembly for uniformly drying the links while rolling them
to maintain a round cross section as they move horizontally from
one end of the assembly to the other.
6. The process of claim 5, further including applying liquid smoke
to the multiple links.
7. The process of claim 6, further including a second dry heating
of the multiple smoked links on a roller conveyor forced hot air
drying assembly for uniformly drying the links while rolling them
to maintain a round cross section.
8. The process of claim 4, further including a first dry heating
the multiple individual links in a roller conveyor forced hot air
drying assembly for uniformly drying the links while rolling them
to maintain a round cross section as they move horizontally from
one end of the forced hot air drying assembly to the other; further
including applying liquid smoke to the multiple links; and further
including a second dry heating the multiple smoked links on a
roller conveyor forced hot air drying assembly for uniformly drying
the links while rolling them to maintain a round cross section.
9. The process of claim 7, further including packaging the multiple
links in fluid tight packages.
10. The process of claim 9, further including cooking to
pasteurization the links in the multiple packages in a second
heated water bath assembly comprising a water bearing housing with
a screw drive section for carrying hot water borne packages
horizontally while they cook.
11. The process of claim 10, further including chilling the
multiple packages in a first chilled water bath assembly comprising
a water bearing housing with a screw section for carrying the
packages horizontally while chilling the water borne packages.
12. The process of claim 11, further including labeling and boxing
the packages.
13. The process of claim 4, wherein the salt of the first aqueous
solution is between 20 to 30% as measured by a refractometer.
14. The process of claim 4, wherein the pH of the first aqueous
solution is between 0.8 and 3.2.
15. The process of claim 4, wherein the temperature of the first
aqueous solution is between 120.degree. F. to 140.degree. F.
16. The process of claim 4, wherein the resident time of a link in
the first section is between 4 to 12 minutes.
17. The process of claim 4, wherein the salt of the second aqueous
solution is between 12% to 22% measured by a refractometer.
18. The process of claim 4, wherein the pH of the second aqueous
solution is between 7.0 and 9.0.
19. The process of claim 4, wherein the temperature of the second
aqueous solution is between 125.degree. F. and 150.degree. F.
20. The process of claim 4, wherein the resident time of a link in
the second aqueous solution is between 4 to 12 minutes.
21. The process of claim 4, wherein the transporting of the
transporting step rotates the longitudinal links at least partly
such that they enter the first heated water bath assembly at an
angle with respect to a longitudinal axis of the first heated water
bath assembly.
22. The process of claim 4, wherein the pH of the first aqueous
solution is between 0.8 and 3.2; wherein the temperature of the
first aqueous solution is between 120.degree. F. to 140.degree. F.;
wherein the salt of the second aqueous solution is between 12% to
22% measured by a refractometer; wherein the pH of the second
aqueous solution is between 7.0 and 9.0; wherein the temperature of
the second aqueous solution is between 125.degree. F. and
150.degree. F.
23. The sausage manufacturing process of claim 3, including a
forced hot air pre-smoke drying step, a liquid smoking step, and a
forced hot air post-smoke drying step after the smoking step; and
wherein the pre-drying step includes providing a roller conveyor
oven and placement of links on a roller conveyor oven and
subjecting them to a preselected air temperature, with a humidity
in the range of 5% to 15%, to evenly dry the product while rolling
the individual links to maintain a round cross section, the pre-dry
time for product in the roller conveyor being 2 to 10 minutes; and
wherein the post-drying step includes the step, following the
liquid smoking step, of providing a roller conveyor oven with an
oven set at a preselected air temperature, with a humidity in the
range of 5% to 15%, the post-dry time being 2 to 10 minutes; while
rolling the individual links and subsequently packaging, completing
cooking, and chilling the food product.
24. The process of claim 1, wherein the pH of the second aqueous
solution is greater than 7.0.
Description
FIELD OF THE INVENTION
Sausage manufacturing, more specifically, the process of using
multiple water baths, as well as pre-smoking and post-smoking
drying steps, in the process of manufacturing of sausages.
BACKGROUND OF THE INVENTION
Sausage making may include (1) ground, fresh sausage products, (2)
emulsion-type sausages, such as frankfurters, wieners, bologna,
liver sausage, (3) fermented sausage products. The production of
sausage dates back centuries. Traditionally, in one embodiment,
meat in an emulsion in a semi-solid form is stuffed into a natural
or artificial casing, such as a collagen casing comprising animal
protein. Collagen casings are made from a naturally occurring
protein, typically bovine collagen from the animal hide is used,
and may be edible.
Casings for sausage and other meat products may be natural or
artificial. Natural casings are sometimes eaten and sometimes
peeled off before being eaten and comprise intestines of animals.
Artificial or sometimes called manufactured casings fall into two
categories. They may be made from natural materials, such as
cellulose collagen, artificial (synthetic) materials, such as
thermoplastics or polymers. Manufactured casings from artificial
materials include those casings made from cellulose from plants or
alginate from seaweed or those casings made from collagen found on
the underside of the hide of some animals. Typically, structural
and functional elements of a system for making sausage or other
coated and extruded meat product depend on the type of casing used
and often machinery used where one type of casing is not suitable
for another type of casing. One type of casing is made from
collagen, which is obtained from the corium layer of selected split
cattle hides. Collagen casings are substantially permeable for
smoke and water vapor.
There are a number of problems associated with the system of
sausage making using collagen as set forth hereinabove. One problem
is the physical size of the machinery required and a second problem
is the cost and maintenance of the machine. As regards to the size,
the prior art, especially the pre-dry (pre-dry meaning before the
smoking step) described above, requires a machine that is huge,
both in the longitudinal and vertical dimensions, but especially in
the vertical dimension. Prior art pre-dry (before smoking)
typically uses a serpentine system of baskets, which has multiple
chains and gears, typically thousands of gears and a hundred or
more baskets. The maintenance alone on such systems may be hundreds
of thousands of dollars a year. What the prior art lacks is a
mechanical system that has a limited vertical profile, which also
lacks gears and baskets.
The time that the standard sausage making processes take is long
and the machines used are large and complex, covering a large area.
In an effort to reduce time and complexity, Applicant provides a
new process indicated at FIG. 1.
Emulsion-type sausage making may be done by a process to co-extrude
a strand of sausage material, which has an inner core of meat
emulsion and an outer surface material that can be coagulated to
provide an encasement for the strand. The outer surface material
may consist of a gel comprising collagen protein. Coagulation of
the collagen normally includes subjecting the extruded strand to a
brine (salt) solution. Coagulation as used herein means the step or
steps of firming up or hardening and stabilization of the casing.
This is primarily done in two ways. First, by removal of water from
the collagen gel and, second, by cross-linking the collagen
fibers.
Collagen can be set by known methods in the preparation of
artificial sausage casing. Co-extrusion takes place into a brine
setting bath. Under the influence of the setting bath or solution,
the collagen is at least partly coagulated or set in contact with
the extruded food stuff and the formed coated food stuff then
emerges from the bath to undergo further process steps.
Stabilization may, however, be by other means, for example, air
drying.
Drying of collagen seems to stabilize the food products. Fibrous
materials, such as collagen casing, may be convection dried as in
the prior art, which is slow and expensive. The convection drying
apparatus of the prior art uses many baskets and convective hot
air. During convective drying, the water filled pores of the
collagen structure collapse because of capillary forces. The
collagen chains begin to stick together.
Collagen is naturally cross-linked. Collagen may be further
cross-linked by chemical cross-linkers (such as those found in
liquid smoke), enzymes, metallic ions or other mechanisms.
Cross-linking may also be achieved by physical methods, such as UV,
temperature treatment, and dry state, radiation, and electron beam.
Cross-linking decreases solubility and susceptibility to enzymes
and microbial attack.
The process for producing co-extruded collagen encased food
product, such as meat products and sausage, typically includes the
extrusion of a meat emulsion with an amount of collagen gel. In a
current process for making co-extruded sausage and links, coarse
ground emulsion is stuffed through a stuffing horn in a
co-extrusion head. The emulsion is co-extruded with vacuumed
collagen gel, which is typically about 4 to 5% collagen at 4%
solids.
One current step in the manufacturing of sausage by co-extrusion
occurs when the meat product (typically in the form of a semi-solid
emulsion) is coated with a collagen gel to produce a meat product.
The meat product is then subject to a solution, for example, a
brine salt that begins dehydration, which starts coagulation or
setting of the collagen gel. The brine usually provides sufficient
set or firmness for the subsequent linking and cutting steps to cut
the product into links. The partial dehydration helps collapse the
collagen onto the emulsion. Yet the casing continues to be
rehydrated during this step due, in part, to rehydration of the
collagen from the inside--that is, from moisture in the meat
emulsion.
The brine solution of this step may be about 22 to 26% salt
dissolved in tap water. This resident time for the product may be
about 18 to 24 seconds to bring about sufficient dehydration for
cutting and linking. The brine may be at ambient temperature.
Following the brine step, the linear (coaxial) meat product is
conveyed through a crimper wheel or other suitable device to link
and cut the sausage to lengths and then the product is conveyed to
a pre-dry (measuring before the smoking step), rocker basket
serpentine system.
The sausage is pre-dried in a rocking basket system at about
150.degree. F. to about 170.degree. F., with low humidity
(typically about 5 to 20%), to evenly dry the product and keep the
product round. The pre-dry time is typically about 20 to 30
minutes. This is typically done in a huge machine, due to the slow
hot air heating required to sufficiently dry the food product. It
has rocking baskets to heat evenly the individual product items and
keep them round.
Typically, following pre-drying (meaning before smoking), the smoke
and cross-link step occurs. The sausage links are transferred from
the pre-dry baskets to the smoking baskets and run through a liquid
smoke, dying and cross-linking solution. The time in the partial
submersion and/or deluge bath is typically about 10 to 15 seconds.
The liquid smoke solution is at about 110.degree. F. to 120.degree.
F.
Following the smoke and cross-link, the post-drying (meaning after
smoking) step is carried out. The sausage links are post-dried on a
conveyor belt at about 150.degree. F. to 170.degree. F. with low
humidity. This will help cross-link the collagen and develop or set
the color. Post-drying typically runs about 8 to 12 minutes, with
the links at about 120.degree. F. to 130.degree. F. (oven
convective air temperature) before going to the vacuum packaging
machine.
SUMMARY OF THE INVENTION
The process for producing co-extruded collagen encased food
product, such as meat products and sausage, typically includes the
extrusion of a meat emulsion with an amount of collagen gel (which
may include a cross-linking agent) coating the exterior of the meat
emulsion.
In one embodiment, Applicant discloses a process for producing a
collagen encased food product comprising one or more of the
following steps. Co-extruding of food emulsion and coating the food
emulsion exterior with a gel comprising collagen and possibly a
cross-linking agent or agents and possibly a coloring agent,
followed by subjecting the continuously co-extruded product to a
brine bath. Next, link cutting, separating the continuous product
into discrete food product items. Next, Applicant contacts the
multiple discrete collagen gel coated food product with a first
aqueous solution, the first solution having a pH range of about 1.0
to 3.2, a salt content of about 12% to 22% by weight, at a
temperature of about 120.degree. F. to about 140.degree. F. for
about 4 to 12 minutes. The first heated solution is gently agitated
and carries the food product from a first point, where it received
from the previous processing step to a longitudinally spaced apart
second point, where it is ready for transfer to a subsequent
aqueous processing step. The next step typically includes
contacting the collagen coated food product with a second solution,
the second warm, agitated, aqueous solution, being a
pre-conditioning solution, to help open the fibers of the collagen.
The second aqueous solution may comprise an aqueous solution of
about 12 to 22% food grade phosphates, and typically has a pH of
about 7.0 to about 9.0, and a temperature of about 125.degree. F.
to about 150.degree. F. This second solution is gently agitated and
carries the food products from the first point where it is received
from the previous step to a longitudinally spaced apart second
point, where it is ready for transfer to a subsequent step, which
may be a pre-drying step. The heated aqueous solution of these two
steps will replace the function of the rocking baskets of the prior
art air dry units by using water pressure and agitation to maintain
roundness, helps coagulate the food product, and prepare it for the
subsequent steps
The next step will typically include a pre-drying step before the
smoking step, and a post-drying step after the smoking step. The
pre-drying step typically includes transfer of the multiple
discrete food items from the water bath machine through the use of
a vibrating laning device for placement of the sausage links or
food items on a novel roller conveyor. The conveyor may carry the
food items through a pre-dry oven at a temperature of about
160.degree. F. to about 210.degree. F., with a humidity in the
range of 5 to 15%, to evenly dry the product while maintaining the
product's roundness. The pre-dry time is usually about 2 to 10
minutes. It will help remove water from the outer portion of the
food product so as to allow the liquid smoke to be absorbed.
The pre-drying step has removed at least some of the water from the
aqueous solution of at least some of the water left by the aqueous
solution used in the steps prior to the pre-dry. The pores of the
casing having been partly opened in the water bath solution and
having the residual water removed therefrom in the pre-dry step,
the food items are ready now for the application of the liquid
smoke. The liquid smoke typically contains a cross-linking agent
and a dye, and may be applied to the still warm product through a
sprinkle system or complete immersion or a combination of the two.
The liquid smoke is typically absorbed at least partially into and
through the casing.
The post-drying step, following the smoking step, typically
includes providing a roller conveyor oven (like that of the
pre-drying step) with an oven set at temperature of about
160.degree. to 210.degree. F. to carry the product, providing an
atmosphere with a humidity approximately 5 to 15%, to help further
coagulate and cross-link the collagen and develop the set of any
color while maintaining roundness. The post-dry time usually takes
about 3 to about 10 minutes. Subsequently, the steps of packaging,
completing cooking, and chilling the food product are
accomplished.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing of the machinery layout and steps of
Applicant's process.
FIG. 2 is a more detailed view of the pre-smoking layout and steps
of Applicant's method.
FIG. 2A is an elevational view of a device for use in Step 2 of the
method.
FIG. 2B is an elevational view of a linker/cutter and water cascade
for use with Applicant's method with the linker cutter situated,
for illustration purposes only, 90 degrees to its actual position
with respect to the water cascade.
FIG. 2B1 illustrates detail of Applicant's water cascade for use in
transporting individual links from the linker/cutter to the first
end of the hot water bath assembly, in elevation.
FIGS. 2C, 2D, 2E, and 2F illustrate additional details and
embodiments of Applicant's water cascade.
FIGS. 3-3F are various views of a novel drying and transport
assembly for use with Applicant's method.
FIG. 4 is an elevational view partly cutaway and FIG. 4A schematic
view of an apparatus for use with water bath steps of Applicant's
method.
FIGS. 4B, 4C, and 4D illustrate perspective views of details of
water bath assembly.
FIG. 5 is an isometric view of a vibrating laning device for use
with Applicant's roller conveyor.
FIG. 6 is an alternate embodiment 50a of a forced hot air roller
conveyor assembly in elevational view.
FIGS. 6A and 6B illustrate the use of the roller conveyor with the
process and the smoke details.
FIGS. 7A and 7B show links that are damaged (unsaleable) and links
that are saleable.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to FIG. 1, an embodiment of Applicant's water bath
co-extrusion sausage manufacturing process 10 with various steps
and devices for manufacturing sausage or other similar food
products, including collagen coated food products, is disclosed.
The process begins with a semi-solid meat emulsion, for example, a
mix of 0-50% beef, 0-75% pork, and/or poultry, and 0-70% other
ingredients including flavoring and a cross linker (optional). The
process includes pre-smoke and post-smoke steps, "wet" working and
treating individual sausage links, "wet" cooking packaged links and
pre and post smoking steps featuring forced hot air drying.
Extrusion, brine and cutting are Steps Nos. 1, 2, and 3. Following
these three steps to set or bond the following with some of their
functions described: Step No. 4 (wet)--heat and coagulate casing;
Step No. 5 (wet)--rinse and open collagen fibers; Step No. 6
(dry)--pre-dry prepare links for smoke; Step No. 7--liquid smoke;
Step No. 8--post-dry prepare links for packaging by drying the
exterior of the product, completing the cross linking, and setting
the color; Step No. 9--package; Step No. 10 (wet)--cook (to
pasteurization); Step No. 11 (wet)--chill; Step No. 12--box cooked
packaged links.
The first two steps are generally known in the prior art and their
structural elements, function, and advantages are generally the
same as those of the prior art (meat stuffers by Vemag, a brine
bath by Reiser). Stuffing heads 11a and 11b are provided for
stuffing meat emulsion and collagen to feed co-extrusion head 12.
In one embodiment, in step 1, ground sausage and vacuum collagen
(about 2.8 to 3.2% collagen to emulsion by weight at about 6%
solids, or about 2 to 7% solids) are fed to co-extrusion head 12.
Collagen is available from DeVro, Columbia, S.C. A Vemag 20e vacuum
stuffier may be used to feed head 11b.
Step 1 which includes stuffing and co-extrusion may include the
adding of a chemical cross-linker (liquid smoke, for example), such
as about 0 to 4% to the collagen weight that is being stuffed, the
cross linker to help coagulation. The co-extrusion head typically
has two cylinders that counter rotate with respect to one another
to align the collagen fibers in a tubular layer of woven collagen
into which the meat emulsion is co-extruded so as to create a
coaxial linear food member--emulsion inside covered with a woven
collagen casing.
In step 2, a brine solution may be used to partly dehydrate
collagen to make it stiff enough and prepare the linear food member
for linking and cutting. In step 2, a continuous (uncut)
co-extruded linear food member product is conveyed through or
subject to a brine bath 13 (see FIG. 2A), as by sprinkling with a
solution of about 22% to about 26% salt, such as sodium chloride or
calcium chloride. The solution may be heated to a temperature of
about 110.degree. F. to 120.degree. F. for soaking the food product
about 5 to 15 seconds. The brine will begin to firm up the collagen
by dehydration, which set will usually be sufficient to cut and
link (see Step 3 below). The stuffed linear food member is then
conveyed through brine bath 13 to a cutter/linker 15. From
cutter/linker 15, it may be transferred via water cascade 200 or
other suitable means to a first hot water bath assembly 16.
While the link cutting step, that is, the third step, may be
performed as known in the prior art, the product in a preferred
embodiment is conveyed and transported through a progressive,
sequential linking/cutting machine 15 to be cut into separate
links. The third step may use, in a preferred embodiment, a
modified sequential cutter (see FIG. 2B). It is noted that the
sequential cutter illustrated is typically not used for collagen,
rather it has been known for use with alginate casing. Moreover,
the use of such a cutter will, following cutting, leave a small
opening at the removed ends of the link, which small opening
exposes the meat emulsion. The alginate type link cutter tends to
result in small openings at the end of the casing, thus exposing
less meat emulsion. A modified VMag sequentially or progressively
closes the ends of the sausage casing before severing the casing
completely to generate links. The VMag cutting/linking machine is
modified in the following manner. The blades (see FIG. 2C)
sequentially squeeze the product as it moves through the cutter,
with the openings getting smaller as the linear member is pulled
through and breaks.
FIGS. 2B, 2B1, and 2C-2F illustrate details of water cascade
transport assembly 200 designed to transport the individual links
of the food product from the end of cutter/linker into a first end
of the hot water bath assembly 16. Such an assembly 200 is designed
to receive moving water 201 from a water source, such as section
16a, with a tube 210, at or near the removed end of the cutter 15
as seen in FIGS. 2B and 2D. An inclined chute 204 may have a hinged
member 202 (FIG. 2B1) or 202a (FIG. 2D) at the upper end thereof,
the hinged member to control the speed of the links as they slide
down to the trough or chute 204. The speed of the water flow (see
pump P, FIG. 2D and 46a of FIG. 4, which may provide solution to
water cascade transport assembly 200 in a preferred embodiment)
determines the speed of the links and will be matched with the
speed of the links as they are carried through the water bath
assembly to insure that there is no "link jam". At the removed end
of the chute is a canted, perforated, tilted plate 211 with
multiple holes to receive the water and links and to direct and
turn them so that they enter the water of the first section
"broadside" (sideways) and so as to avoid the links striking the
walls of screw 30 or basket/shell 300 (see FIGS. 2E and 2F). The
broadside turn is to protect the open ends where the emulsion is
exposed that will help turn the sausage sideways or at least
partially sideways as seen in FIGS. 2B and 2B3. The links will
typically enter an opening at the first end of the hot water bath
assembly partially or fully rotated so as to protect the exposed
ends of the food product.
FIGS. 2B and 2D illustrate the use of a spray bar 209 with jets
209a to direct the first aqueous solution (from first section 16a)
onto the screw or other parts of assembly 16 to prevent product
sticking to the walls thereof.
FIGS. 2, 2D, 2F, 4, 4A, 4B, 4C, and 4D illustrate a first combined
water bath and cooking assembly 16 (sometimes referred to as a hot
water bath assembly or water bath assembly) for use in Steps 4 and
5. Baskets or shells 300/302 contain screws 30/31 partially
submerged in heated water W (that is, an aqueous solution) in first
sections 16a/16b with air jets 36 for generating turbulence.
Perforated inspection doors 301 are provided in both shells. The
screws and turbulence causes the food product FP to be buoyantly
and gently agitated while moving longitudinally, so they remain in
their original round shape and not damage the casing or ends.
Housing 18 contains rotating first and second shells 300/302 with a
transfer plate 304 (see FIG. 4B) between. The function of the first
water bath/heating step 4 is to bond or set (at least partly) the
casing so that it is firm. The casing typically has multiple layers
of collagen, and a collagen layer adjacent the emulsion. The first
bath will firm up the delicate casing by helping adjacent layers
bond one to the other and will help the collagen layer adjacent the
emulsion stick or set to the emulsion.
FIGS. 2B, 2D, 4, and 4A-4D show hot water bath assembly 16 having a
first section 16a and a second section 16b for the first and second
water bath steps 4 and 5. Hot water bath assembly 16 may have an
outer housing 18. Outer housing 18 typically includes a cylindrical
housing portion 20 and a first end wall 22, a divider wall 29, and
a second end wall 24. A hinge 25 may be provided and the outer
housing 18 may be hinged to pivot, thus providing a top half
portion 18a or cover and a bottom half (water holding) portion 18b.
End walls 22/24 typically have end wall openings 26/28 for transfer
of links into the water bath assembly 16 or out of the baskets
300/302 of the assembly. The baskets have perforations and doors
(see FIG. 4C). Food product FP (also called links) is transferred
from linking/cutting machine 15 to water W at a water level WL
typically maintained below the top perimeter of bottom half portion
18b. Rotating baskets 300/302 with screws 30/31 are provided with
helical blades 32 for rotating in the water W containing food
product FP to help move product axially or longitudinally from
opening 26 to opening 28, while the food product is being heated
and treated with the chemicals contained in the water. A heater 48a
is provided to heat the first aqueous solution, in first section
16a. As set forth below, the food product is subject to two
separate baths, with the water in each typically both but at least
the first section having separate chemical makeup and heat, water
flow, pH and screw controls.
It is seen that food product is transferred between section 16a and
16b and then transferred out of section 16b to laning device 17.
The method of transfer is accomplished without destroying the
integrity of the casing or product and product ends. The method of
water transport into the first end of 16a has been illustrated and
explained previously. The method of transport from section 16a to
section 16b may be accomplished as seen in FIGS. 4B and 4C, with a
tilted transfer plate 304. Lifting plates 307 may be provided in a
trader wheel (16c FIG. 4A) or section just upstream of the transfer
point between section 16a and 16b as seen in FIGS. 4B and 4C.
Lifting plates 307 are perpendicular to the end wall 300a of shell
or basket 300, so that the product may be lifted above the upper
upstream end plate 304 (see also FIG. 4C). FIG. 4D illustrates a
manner of transferring product out of the end wall opening 38 of
second section 16b by the use of lifting or catch plates 309 at the
end of basket 302. Product is lifted as screw 31 and basket 302
rotate together in the direction indicated in FIG. 4D. Product
rolls off the lifting or catch plate 309 as it is picked up from
the water and rolls through chute 314 which may have an open top
314a and a canted bottom wall 314b to allow the product to roll
onto the laning device 17.
Air jet assembly 34 may be provided with multiple, housing engaging
air jets 36 in the lower portion 18b. A compressor 38 and manifold
40 may be provided to provide compressed air to the multiple air
jets, the compressed air being injected into the separate aqueous
solutions below water level WL to provide gentle agitation to help
maintain food product integrity and for helping the chemical and
physical reactions generated by the chemicals and heat of the water
W. Two water solution handling systems 42a/42b may be provided,
including multiple water pipes 44, engaging separate pumps 46a/46b
and heaters 48a/48b to provide separate closed loop (with makeup
water) circulation of heated water solutions to the lower portion
18b of sections 16a/16b. The first section 16a is typically about 8
feet long; the second section 16b though similarly constructed may
be shorter, typically about 4 feet long. The two sections 16a/16b
may be of a single assembly as seen in FIGS. 2 and 4 or two
separate units. The first section will typically contain between
about 600 and 900 gallons of solution, the second section between
about 300 and 600.
In one embodiment, an aqueous solution in the first section 16a has
about 12 to 22% sodium chloride or other suitable salt (measured by
refractometer) with a pH adjusted to between about 0.8 to 3.2 (or,
in another range, about 1.8 to about 2.0), using organic food grade
acids or a blend of acids, (such as acids available from pH Fresh
Technology). The water solution is heated by means of heater 48 in
one range to between about 100.degree. F. to about 160.degree. F.
(or between about 120.degree. F. and 140.degree. F.), depending
upon product sizing and desired casing characteristics.
The product remains in the first aqueous salt and acidic bath and
hot water bath assembly 16 from about 4 to about 12 minutes,
depending upon product size and desired casing characteristics, and
is then transferred through a bucket dump or trader wheel 16c see
FIG. 4A or other suitable transfer device, such as a transfer plate
304 (see FIG. 4B), between basket 300 of section 16a and 302 of
section 16b. FIG. 4B also shows the use of internal drive wheels
306/308 for engaging motors M1 and M2 for internal screw drive (see
FIG. 4 for external screw drive) to a second water bath/heat step.
While the first water bath heating step provides a warm acidic
aqueous environment, the second water bath typically provides an
aqueous solution with a pH of about 7.0 to about 9.0, and may
include about 12% to about 22% solids by refractometer of food
grade phosphates (sodium or di-potassium) or other suitable salt to
help rinse the casing of salt from the previous step and open the
collagen fibers so as to help the casing accept liquid smoke of the
smoking step. The aqueous non-acidic solution is heated to about
125.degree. F. to 150.degree. F. in one range depending upon
product size and desired casing characteristics (internal
temperature of emulsion should reach about 117.degree. F.). The
links are continually lightly agitated to ensure that the product
remains in its original round link shape and may remain in this
second water bath/heating step for about 2 to about 10 minutes,
depending upon product size and desired casing characteristics,
where it is transferred to the pre-dry oven via a vibrating
collated laning device 17 (see FIG. 5).
This second water bath step is conditioning of the casing for
pre-drying (meaning before smoking) and smoking. The phosphates or
other salt of the second bath are chosen to keep the moisture out
of the collagen so it doesn't lose its integrity. Moreover, the
heat, salt and pH combine to open up the fibers in the collagen to
prepare it for the pre-dry, smoke, and cross-link steps set forth
below. The open fibers allow the smoke and dyes or other additives
to more easily be taken up into the casing. The use of the
indicated pH and the phosphates (or other suitable salt) are
designed to substantially remove the salt of the first water bath
and to remove and neutralize the acid of the product that remains
from the first step.
It is noted that the two water bath steps also use the water to
move the sausage horizontally. That is to say, the machinery
illustrated in FIGS. 2 and 4, showing the two water baths is
designed to use the water as a transport medium to physically move
the links at the same time it is being treated by the heat and
chemicals of the two steps. The effectiveness of the water and the
means of wet heating and transport allow for, among other things,
the advantages of a physically smaller machine, especially in terms
of length and height, than that required by most prior art
processes, to achieve the same pre-smoke preparation, for the
sausage or other meat products. A device that may be useful in
practicing Applicant's water bath steps is a LYCO Rotary Drum
Cooker (72''.times.8' or 4'), from LYCO Mfg., Columbus, Wis.
modified according to the structural and functional details set
forth herein.
In FIG. 4, controls 49a/49b is provided to control input into
motors M1/M2 to independently adjust the speed of the two screws to
control the rate of product flow in each of the two sections
16a/16b, and also to control the temperature of the water in each
section. Controls may also be provided for pH meters 310/312 (pH
adjustment) and refractometers 315/316. FIG. 4 discloses heaters
48a/48b to independently control heating the solution in the two
sections 16a/16b. Air jets 36 in conjunction with compressors 38
and manifold 40 comprise an air jet assembly 34. The air jet
assembly helps support the products (provides bouancy and some
turbulence), as the air jets are located at or near the bottom of
the housing, so that the products do not all settle. They also help
keep the product round and keep the sticky collagen casing on the
products from sticking one product to the other.
FIG. 4 also illustrates a makeup water assemblies 318/320,
including makeup water (fresh 318a or salt water 318b) reservoirs
with a pair of valves (318c on salt water, 318d on fresh water) for
providing makeup water (fresh or salter water) to each section, as
water is lost or as solids content goes out of range. Independent
valves 318c/318d unnumbered on 320 may control the water levels of
each section independently and/or solids content when coupled with
appropriate water level sensors and solids sensor (refractometer)
to maintain the level of water preselected level and the solids
controls of salt content of each separate section is maintained by
refractometers 315/316 in each solution controlling the valves, so
as to selectively add salt water if solids get too low or fresh
water if solids too high. If the solids are in the proper range,
both valves will be open together at appropriate flow to add keep
water near the proper level. In addition, the pH in each of the
sections 16a/16b (at least first section 16a) may be automatically
monitored and controlled thru pH meters and pH controls.
Pumps 46a/46b to help control the flow of water through the
sections, which pumps may be controlled through controller 49a/49b.
In one embodiment, the pumps 46a/46b cause the water to flow in the
same direction as the screws are moving the food product FP.
The brine and the salt solutions of the previous steps will have
the effect of dehydrating the collagen and partially the emulsion
so as to, among other things, help maintain integrity of the
casing. The smoke pre-drying step will also further dehydrate, by
the application of warm air to the product, to further help set and
bond the casing. Cross-linking of the collagen fibers one to the
other will primarily take place during the liquid smoking step as
more further set forth below. The first and second heating steps
and the first and second aqueous solutions will help prepare the
multiple links for smoking and cross-linking. In the first heating
step, a combination of salt pH time and water temperature help the
protein layers of collagen bond one to the other and the lowest
layer of the collagen and the casing to bond to the emulsion. The
second heating step and the second non-acidic aqueous solution will
help rinse some of the salt of the previous step (for flavor
purposes) and help open the fibers of the collagen casing to help
the liquid smoke get taken up into the casing. In both the first
and second heating steps, the physical integrity of the collagen
casing, which may be delicate at this point, needs to be maintained
and improved. Moreover, the open ends, where the emulsion is
exposed from the casing, need to be maintained in a uniform
condition.
FIGS. 7A and 7B are provided to appreciate the difference between
the links that are unacceptable because the casing is either broken
or the ends are too open or irregular and a link that is
satisfactory and saleable. The physical integrity of the casing and
the links are in part a function of the mechanical energy of the
water bath assembly. The mechanical energy, if it is too high as a
result of too much product, too much turbulence (jets), or too much
jostling (water flow and/or screw speed), can result in damaged
casing. Thus, by adjusting these parameters, to slow water, to
reduce the amount of product coming into the water bath assembly or
to reduce turbulence, will help achieve the proper casing
integrity.
It is seen that casing bonding will be assisted by dehydration,
both with the use of brine and with the use of dry heat, up to the
smoker and by the use of acid and heat in the first bath (followed
by rinse and fiber conditioning in the second bath). The resident
time of the product, the temperature, the pH, the percent of
dissolved solids, and other relevant factors may be controlled to
help ensure that there is a proper set or bonding of the collagen
casing when it leaves the first water bath section 16a. This may be
done by manually inspecting food product in sections 16a or as it
comes out of the water bath assembly 16 and tugging slightly or
lifting on the collagen casing to see that it has the proper
elasticity and toughness and does not fall apart. Moreover, a quick
visual inspection will determine whether or not there are physical
tears in the collagen casing that will require adjustment of
mechanical energy and/or the chemistry and physical conditions of
either (or both) the first or second bath. If there is no
mechanical damage to the product, but poor bonding, then adjusting
the chemistry or heat may help to get proper bonding (see FIGS. 7A
and 7B). The bonding of the casing to the emulsion can be checked
by lifting or rolling back the casing where it meets the emulsion
at the link ends. Proper boding can be both seen and felt. Solids
may be increased for better bonding, less than 12% solids is
typically too low regardless of pH. Solids too high is typically
not a problem for bonding, but is a problem for flavor retention of
the salt. pH may be lowered to help get proper bonding or the
temperature may be lowered (while going to a longer resident time).
Moreover, increased resident time alone in the baths may increase
proper bonding.
The function of the first drying step is to maintain proper round
cross section to the links as well as drying of the casing (the
product is wet coming out of the water bath assembly) so that when
then the liquid smoke is applied, it may be taken up into the
casing. If the links are wet when they go into liquid smoke, then
this impedes the proper take-up of liquid smoke. Smoking of the
post-drying step is, in part, to remove the dampness created by the
liquid smoking while maintaining and providing a uniform roundness
to the product.
FIG. 5 illustrates the collated vibrating laning device 17 (Meyer
Mfg.) out of hot water bath assembly 16 into forced hot air roller
conveyor forced hot air drying assembly 50. The multiple randomly
oriented individual food product items are received from the water
bath device onto a flat portion of laning device 17 as seen in FIG.
5. The flat portion is tilted slightly and vibrates back and forth
and, as it does, the vibrating food products are laned into
multiple vibrating lanes, here, five, 17a/17b/17c/17d/17e. A
staggered trailing edge 19 deposits the collated or laned food
items as they align with the rollers of roller conveyor forced hot
air dryer 50 as seen in FIG. 5.
Step 6 is a smoke pre-drying step and may utilize any prior art air
dry oven with a temperature set to about 160.degree. F. to about
210.degree. F., with a low humidity (typically about 5 to 15% or
less than 20%) to evenly dry the product, the pre-dry time is
typically about 2 to 10 minutes, as the product coming from the
second water bath (step 5) is already at about 117.degree. F.
internal temperature. In a preferred embodiment, the pre-drying and
post-drying steps may be done through use of drying and product
roller conveyor forced hot air dryer 50 as seen in FIGS. 3-3F, 6,
and 6A. The pre-drying of the individual links, in one embodiment,
helps to treat the exposed ends of the individual cut sausage by
dehydration.
Following the pre-drying step, the sausage may be transferred via
conventional means, such as a conveyor or via roller conveyor
forced hot air dryer 50 to a liquid smoking chamber 116 (see FIGS.
6A and 6B) for step 7, the smoking step, where sausage links are
exposed to a liquid smoke, dying (coloring) and a cross-linking
solution, to cross-link and/or color the product in ways known in
the art. For example, a smoke machine or chamber 116 that provides
partial submersion and/or a spray bath from spray nozzles 116a like
for about 10 to 15 seconds in a solution of liquid smoke which may
be heated to about 110.degree. F. to about 120.degree. F. The
cross-linking provides stability to the casing, including the
collagen casing.
Step 8 is a post-drying step, where the sausage product continues
to a post-dry oven and is dried typically on the same machinery or
the roller conveyor forced hot air drying assembly 50 used in the
pre-drying step (step 6) and set at a temperature to about
160.degree. F. to about 210.degree. F., a low humidity (typically
about 2 to 10%) to help dry the product, coagulate the cross-linked
collagen and/or set the color. Post-drying is typically about 3 to
10 minutes and the links typically are about 120 to 130.degree. F.
going to the vacuum packaging machine 118, Step 9, such as vacuum
packaging machines known in the art.
The final process packages the product, finishes the cooking
(pasteurization), and chills it in ways known in the art or by
using applicant's novel machine. Applicant's packaging Step 9 is
illustrated in FIG. 1 and may be achieved by using prior art
packaging machinery 118, such as made by Multivac, for packaging
multiple links in a single package. Applicant's cook/chill Steps
10/11 may be achieved in cook/chill machinery 120 that is similar
to the modified LYCO illustrated in FIG. 4, but utilizing packaged
goods moving through the water bath/screw combination and, wherein,
following the cooking is a chill step with the packaged product
moving through a chill section of the water bath assembly or a
separate water bath with chill temperature control and heat
exchanger (cooler) and separate speed control on the screws. Water
alone may be used in the cook/chill sections typically at about
185.degree. F. temperature (sufficient to pasteurize the product)
in the cook section (16a) (to get internal temperature of links to
at least 160.degree. F.) and at 36.degree. F. temperature in the
chill section (16b). From the cook/chill steps 10/11, Applicant
goes to box-off of the packaged products for subsequent shipping,
the box-off step way achieved through machinery by methods known in
the art.
One of the advantages of Applicant's system is it is low profile
and does not require extensive vertical machinery (see FIG. 2). The
aspect ratio, length/height for the machine of this system is
typically 2 or greater or preferably 3-20, where length is from
product intake to boxing, and height is from the support surface to
the highest point of any machine in the line. More specifically,
Applicant's system is a system in which a collagen gel coated food
emulsion, such as sausage, may be prepared without the large
rocking basket dryer system of the prior art, instead using
Applicant's water bath to make more efficient use of space. In one
embodiment, Applicant's entire system from the stuffing through
boxing can be achieved in a vertical room which has a maximum of 8'
to 12' ceilings and a linear footprint on a support surface, such
as a floor of between about 60 and about 180 feet. It will be seen
in one embodiment that the machines may align parallel to one
another, for example, see FIG. 2, in which the steps after the
post-dry step, including packing and a cook/chill, are linearly
arranged adjacent pre-dry, smoke, and post-dry. Applicant has
endeavored, in part, to reduce the physical size of the equipment
necessary in the process of making the collagen coated meat product
and to reduce the maintenance cost by eliminating gears and
baskets.
FIGS. 3-3F disclose details of a roller conveyor forced hot air
dryer assembly 50 for use transporting multiple food items while
heating them. Roller conveyor forced hot air dryer assembly 50 may
include an external housing 63 and one or more air handling units
top 52a/bottom 52b designed to move hot air about the product as
the product is being transported. Air handling units 52a52b each
may include a fan assembly 56, including a motor 60, a heating
element 58, and a shroud 65 to direct air to the food products on a
roller/conveyor assembly 54 and for engaging the fan and the
heating element. Heating element 58 heats moving air, which fan
assembly 56 and shroud direct to the food product. There may be an
air handling unit above 52a and below 52b the rollers as seen in
FIG. 3 to help ensure even heating and both fan and heat controls
(not shown) may be used to control air flow and hot air
temperatures.
The food product, such as sausage links or frankfurters, is carried
on a food product roller/conveyor assembly 54, which may include a
frame 62. Housing 63 may engage, or at least partly enclose, both
the air handling units 52a/52b and at least partly enclose
roller/conveyor assembly 54. Legs 73 may engage frame 62 and/or
housing 63 to support roller conveyor forced hot air dryer assembly
50. Frame 62 is designed to be stationary and acts to hold other
static or dynamic elements of the food product roller/conveyor
assembly 54 in spaced relation. Frame 62 may include multiple
transverse members 64, the multiple transverse members engaging
inner longitudinal members 66/68 and outer longitudinal members
70/72 (see FIG. 3E). The inner and outer longitudinal members being
paired laterally as seen in FIG. 3A. A rack 74 with upstanding
teeth 76 thereon is seen to rest in longitudinal members 70/72 and
is directed upward (FIG. 3B or 3C) or may be tied into and
suspended above frame 62 and directed downward (see FIG. 3). Rack
74 is positioned such that teeth 76 engage drive sprockets 110 at
the ends of roller members 102/104 (see FIG. 3C).
The roller/conveyor assembly 54 is provided and may include a pair
of link chains 80 configured as set forth herein. Link chain 80 may
be supported vertically spaced apart above the inner longitudinal
members 66/68 in the manner set forth in FIG. 3B by support member
81. The links 82 of link chain 80 may include mounting brackets 84.
Mounting brackets 84 may include depending members 86 and
horizontal members 88, the two members of one link spaced apart on
chain link axles 87 (see FIG. 3B). Horizontal members 88 are
adapted to receive laterally spaced apart roller mounting blocks
90/96 through the use of fasteners 95, the paired chain and
mounting block assemblies on either side of the frame are as seen
in FIG. 3A (chain omitted for clarity).
In FIG. 3A, mounting block 90 is seen to have a first and second
92/94 channels and mounting block 96 is seen to have first and
second channels 98/100 therein. The channels are adapted to receive
the removed ends of roller members 102/104 (see FIG. 3B), these
paired roller members 106 being supported in mounting blocks 90/96,
so they may roll therein. As seen in FIG. 3F, at the removed ends
of axle support roller members 102/104 is a land 108 (to, along
with roller drive sprocket 110, prevent left or right movement of
roller members) on one end to position the removed end against the
outer wall of the mounting block and the roller drive sprocket 110
at the opposite end of the land. Roller member drive sprocket 110
will cause rotation of the axle support roller members as they are
driven from one end of the frame to the other as seen in FIG. 3.
This is due to chain 80 pulling the roller/conveyor assembly 78,
which includes drive sprockets 110 across teeth of rack 74 (see
FIG. 3, upper rack; FIG. 3B, lower rack). Arrow A in FIG. 3 shows
the longitudinal movement of the cylindrical food product resting
between the rollers and Arrow B indicates the rotational direction
of the food product. The combined rotation and longitudinal
movement helps ensure even drying while maintaining the round
physical configuration of the food product. A pair of motor driven
chain drive sprockets 114 are located on either end of a frame 62
mounted drive axle 112, which may be motor driven, as with an
electric motor by a speed controller. FIG. 3 shows a setting finger
113, which may be attached to the frame and is provided so that the
chain passes by, but the teeth of the roller member sprocket will
strike it as the teeth pass by. For example, in FIG. 3, you will
see that the chain is moving from left to right, and the roller
member drive sprocket 110 moving from left to right is just about
to have one of its teeth strike setting finger 113. When that
happens, it will set the roller member drive sprocket in a proper
position so it does not jam when it strikes the leading edge of
rack 74.
FIGS. 6A and 6B illustrate alternate preferred embodiments of a
roller conveyor forced hot drying assembly 50a, which comprises a
roller conveyor assembly 54 with an air handling unit 252. The
function of the roller assembly is to carry individual links of
food product aligned on the rollers through a forced air heater to
roll the food product while heating it in a manner that provides
uniform and sufficient heat as well as maintains the roundness and
the form of the product and, to do so, in the machine that has a
low profile. Illustrated is one such assembly 50a in which the air
handling unit 252 is designed to provide substantially uniform
forced hot air onto the product as it is being moved. Rectangular
housing 263 may have openings on either end thereof as seen in FIG.
6. A plenum assembly 220 is provide engaged to housing 263 which
plenum assembly may include a heater 222 and fan 224. The fan draws
in the air through controlled openings on intake 223 and past a
burner 228, which may include a natural gas conduit 226, burner 228
adjacent the fan. Engaged to the plenum assembly 220 may be a hot
air distribution system 230, which is a system of pipes that will
typically include multiple manifolds 232a/232b/234a/234b (some may
be above product, some below) and multiple air jets 236 as laid out
in FIG. 6 in one embodiment to provide forced hot air so the hot
air jets to the top and bottom of the product as it rolls past the
jets. Here, a pair of upper manifolds 232a/232b and lower manifolds
234a/234b are engaged to the plenum to direct the airflow to the
jets. Air temperature control by a temperature sensor 240 that may
be placed within the interior of housing 263, so to control the air
temperature and, therefore, the food product temperature therein by
turning the burner up, down or off. Typically, this temperature may
be controlled between about 170 and 250.degree. F. or about
195.degree. F. In addition, a heat exhaust 242 engaged to the
interior of housing 263 may be controlled, for example, through a
servo controlled damper 244, to control the humidity within the
interior of the housing.
The heat may be controlled by turning the burner on and off or up
and down, and the heat is typically maintained at about 195.degree.
or between 170 and 250.degree. F. The humidity 263 may be
controlled by adjusting fresh air which typically is dryer than the
air inside housing. This is done by controlling the adjustable
damper valve 244, which may have a servo motor and be in one
embodiment 50% open, the damper may be within heat exhaust 292.
Opening the damper will typically drop humidity by allowing more
air to enter through fresh inlet 223, closing the damper will
increase humidity (unless it is a very wet or humid day).
FIG. 6A illustrates that a single roller conveyor assembly 54 may
be used for carrying product. FIG. 6B illustrates that smoker 116
may have liquid smoke jets or sprayers 116a for spraying product or
links on top of roller conveyor assembly 54 and may have a catch
pan 116b below to catch liquid smoke.
Although the invention has been described with reference to a
specific embodiment, this description is not meant to be construed
in a limiting sense. On the contrary, various modifications of the
disclosed embodiments will become apparent to those skilled in the
art upon reference to the description of the invention. It is
therefore contemplated that the appended claims will cover such
modifications, alternatives, and equivalents that fall within the
true spirit and scope of the invention.
* * * * *